CA2238250A1 - Chopped carbon fibers and a production process thereof - Google Patents

Chopped carbon fibers and a production process thereof Download PDF

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Publication number
CA2238250A1
CA2238250A1 CA002238250A CA2238250A CA2238250A1 CA 2238250 A1 CA2238250 A1 CA 2238250A1 CA 002238250 A CA002238250 A CA 002238250A CA 2238250 A CA2238250 A CA 2238250A CA 2238250 A1 CA2238250 A1 CA 2238250A1
Authority
CA
Canada
Prior art keywords
carbon fibers
fiber bundle
chopped carbon
sizing agent
chopped
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002238250A
Other languages
French (fr)
Inventor
Tetsuyuki Kyono
Keizo Ono
Haruo Obara
Toshiyuki Miyoshi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toray Industries Inc
Original Assignee
Toray Industries Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toray Industries Inc filed Critical Toray Industries Inc
Publication of CA2238250A1 publication Critical patent/CA2238250A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
    • D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
    • D01F9/12—Carbon filaments; Apparatus specially adapted for the manufacture thereof
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/55—Epoxy resins
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/40—Fibres of carbon
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2918—Rod, strand, filament or fiber including free carbon or carbide or therewith [not as steel]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/294—Coated or with bond, impregnation or core including metal or compound thereof [excluding glass, ceramic and asbestos]
    • Y10T428/296—Rubber, cellulosic or silicic material in coating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2962—Silane, silicone or siloxane in coating

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Reinforced Plastic Materials (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Inorganic Fibers (AREA)
  • Paper (AREA)
  • Preliminary Treatment Of Fibers (AREA)

Abstract

Chopped carbon fibers, comprising a set of chopped carbon fibers impregnated with a sizing agent, the short fiber bundle pieces constituting the set, having an average weight per unit length of 1.7 to 4 mg/mm in the fiber length direction and a coefficient of variation of 30 to 60% in the distribution of weights per unit length in the fiber length direction. The chopped carbon fibers can be used for molding a carbon fiber reinforced composite product.

Claims (16)

1. Chopped carbon fibers, comprising a set of chopped carbon fibers impregnated with a sizing agent, the short fiber bundle pieces constituting the set, having an average weight per unit length of 1.7 to 4 mg/mm in the fiber length direction and a coefficient of variation of 30 to 60% in the distribution of weights per unit length in the fiber length direction.
2. Chopped carbon fibers, according to claim 1, wherein the rate of the number of short fiber bundle pieces respectively with a weight of not smaller than double the average weight to the total number and the rate of the number of short fiber bundle pieces respectively with a weight of not larger than 1/3 of the average weight to the total number are respectively less than 10%.
3. Chopped carbon fibers, according to claim 1 or 2, wherein the short fiber bundle pieces are almost rectangular in the cross sectional form and vary in the side length, and the average value in the side length is in a range of 1.5 to 6 mm while the coefficient of variation in the side length is in a range of 25 to 40%.
4. Chopped carbon fibers, according to any one of claims 1 through 3, wherein the sizing agent is mainly composed of one or more as a mixture of urethane resins, acrylic resins and epoxy resins.
5. Chopped carbon fibers, characterized by having the following property:
0.5 ~ W1 2/ (K ~ W2) ~ 1 .5 K: Constant = 597 W1: Weight of carbon fibers packed in a container with a capacity of 200 cc (g) W2: Maximum weight of carbon fibers capable of piling on a flat measuring table made of stainless steel with a diameter of 8 cm
6. Chopped carbon fibers, according to any one of claims 1 through 3, which have the following property:
0.5 ~ W12/(K~W2) ~ 1.5 K: Constant = 597 W1: Weight of carbon fibers packed in a container with a capacity of 200 cc (g) W2: Maximum weight of carbon fibers capable of piling on a flat measuring table made of stainless steel with a diameter of 8 cm
7. A process for producing chopped carbon fibers, comprising the steps of applying a sizing agent as a water dispersed sizing agent to a continuous carbon fiber bundle consisting of 20,000 to 150,000 filaments, controlling the packing density in a range of 5,000 to 20,000 D/mm, cutting the carbon fiber bundle in a wet state of 10 to 35 wt% in solution content at the time of cutting, and drying with vibration at a solution content of 15 to 45 wt% before drying.
8. A process for producing chopped carbon fibers, according to claim 7, wherein the solution content at the time of cutting and that before drying are respectively 15 to 35 wt%.
9. A process for producing chopped carbon fibers, according to claim 7, wherein the carbon fiber bundle is cut in a wet state of 10 to 30 wt% in solution content, and water or a sizing agent solution is additionally applied to the chopped fiber bundle before drying, to achieve a solution content of 25 to 45 wt% before drying.
10. A process for producing chopped carbon fibers, according to claim 9, wherein the additional application of water or a sizing agent solution to the chopped fiber bundle before drying is effected by spraying.
11. A process for producing chopped carbon fibers, according to claim 7, wherein the continuous fiber bundle impregnated with a sizing agent solution is passed through a nozzle hole, to control the solution content.
12. A process for producing chopped carbon fibers, according to claim 7, wherein the sizing agent solution is applied to the continuous carbon fiber bundle by guide oiling to supply the sizing agent through a guide.
13. A process for producing chopped carbon fibers, according to any one of claims 7 through 12, wherein the cut short fiber bundle pieces as wetted by a sizing agent solution are dried in hot air while being vibrated at 5 to 25 cycles per 1 second.
14. A process for producing chopped carbon fibers, according to any one of claims 7 to 13, wherein the packing density of the carbon fiber bundle wetted by a sizing agent solution immediately before cutting is in a range of 8,000 to
15,000 D/mm.
15. A process for producing chopped carbon fibers which are impregnated with a sizing agent and are in a form of short fiber bundle pieces having an average weight per unit length of 1.7 to 4 mg/mm in a fiber length direction and a coefficient of variation of 30 to 60% in a distribution of weight per unit length in the fiber length direction, which process comprises:
applying an aqueous dispersion of a sizing agent to a continuous carbon fiber bundle consisting of 20,000 to 150,000 filaments having a single filament fineness of 0.3 to 2.0 denier and a twist of 0 to 10 turns/m, controlling a packing density of the continuous carbon fiber bundle in the range of 5,000 to 20,000 D/mm, cutting the continuous carbon fiber bundle in a wet state while a weight ratio of the aqueous dispersion of the sizing agent to the carbon fiber bundle is 10 to 35 wt%, and drying the chopped carbon fibers in hot air while vibrating the chopped carbon fibers, wherein the weight ratio of the aqueous dispersion of the sizing agent to the chopped carbon fibers is in the range of 15 to 48 wt% before drying.
16. A thermoplastic resin composition consisting essentially of 3 to 70 wt% (based on the composition) of the chopped carbon fibers as defined in any one of claims 1 to 6 or produced by the process as defined in any one of claims 7 to 15 and 97 to 30 wt% of a thermoplastic resin as a matrix for the chopped carbon fibers.
CA002238250A 1997-05-23 1998-05-22 Chopped carbon fibers and a production process thereof Abandoned CA2238250A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JPHEI9-150477 1997-05-23
JP15047797 1997-05-23
JPHEI9-202561 1997-07-11
JP20256197 1997-07-11

Publications (1)

Publication Number Publication Date
CA2238250A1 true CA2238250A1 (en) 1998-11-23

Family

ID=26480061

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002238250A Abandoned CA2238250A1 (en) 1997-05-23 1998-05-22 Chopped carbon fibers and a production process thereof

Country Status (8)

Country Link
US (2) US6066395A (en)
EP (1) EP0881312B1 (en)
KR (1) KR100479546B1 (en)
CN (1) CN1105210C (en)
CA (1) CA2238250A1 (en)
DE (1) DE69818344T2 (en)
MY (1) MY114978A (en)
SG (1) SG65070A1 (en)

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Publication number Priority date Publication date Assignee Title
US6066395A (en) * 1997-05-23 2000-05-23 Toray Industries, Inc. Chopped carbon fibers and a production process there of
JP3807066B2 (en) * 1998-01-06 2006-08-09 東レ株式会社 Sizing agent for carbon fiber, carbon fiber sized by the same, and composite material comprising the same
DE60204373T2 (en) * 2001-03-16 2006-05-04 The Goodyear Tire & Rubber Co., Akron Triebriemen with cut carbon fibers
WO2005012604A2 (en) * 2003-07-31 2005-02-10 Mitsubishi Rayon Co., Ltd. Carbon fiber bundle, process for producing the same, and thermoplastic resin composition and molded article thereof
US7188462B2 (en) * 2004-08-06 2007-03-13 Stowe-Pharr Mills, Inc. High-strength spun yarn produced from continuous high-modulus filaments, and process for making same
WO2006032406A1 (en) * 2004-09-21 2006-03-30 Cordenka Gmbh Flowable pellets based on cellulose textile fibres and a method for the production thereof
TWI352146B (en) * 2005-07-08 2011-11-11 Teijin Aramid Bv Method for improving filament cohesiveness of chop
GB0619401D0 (en) * 2006-10-02 2006-11-08 Hexcel Composites Ltd Composite materials with improved performance
US7638110B1 (en) * 2008-07-02 2009-12-29 Toho Tenax Co., Ltd. Carbon fiber
DE102008038295B4 (en) * 2008-08-18 2013-11-28 Eads Deutschland Gmbh Granulation and stabilization of resin systems for use in the manufacture of fiber composite components
US8361610B2 (en) * 2009-07-02 2013-01-29 E I Du Pont De Nemours And Company Composite with low content of metal
WO2011002867A1 (en) 2009-07-02 2011-01-06 E. I. Du Pont De Nemours And Company Semiconductor manufacture component
JP5700496B2 (en) * 2010-03-08 2015-04-15 東邦テナックス株式会社 Carbon fiber chopped strand and method for producing the same
US8309644B1 (en) 2011-08-29 2012-11-13 GM Global Technology Operations LLC Methods of treating carbon fibers, fiber-reinforced resins, and methods of making the fiber-reinforced resins
CN104105743B (en) 2012-01-31 2016-10-26 帝人株式会社 Random mat and fibre reinforced composites
WO2013166132A1 (en) * 2012-05-01 2013-11-07 Continental Structural Plastics, Inc. Process of debundling carbon fiber tow and molding compositions containing such fibers
CN104520358B (en) 2012-07-26 2017-05-24 帝人株式会社 Random mat and molding of fiber-reinforced composite material
US20150158984A1 (en) 2012-07-31 2015-06-11 Teijin Limited Random Mat and Fiber-Reinforced Composite Material Shaped Product
WO2014021315A1 (en) 2012-08-01 2014-02-06 帝人株式会社 Random mat, and compact of fibre-reinforced composite material
JP5717928B2 (en) 2012-09-21 2015-05-13 帝人株式会社 Manufacturing method of composite material
CN104602882B (en) * 2012-10-25 2016-08-24 东丽株式会社 Can punching press sheet material
WO2014081002A1 (en) * 2012-11-26 2014-05-30 三菱レイヨン株式会社 Chopped carbon fiber bundles and method for producing chopped carbon fiber bundles
US9920197B2 (en) 2012-12-20 2018-03-20 Cytec Technology Corp. Liquid binder composition for binding fibrous materials
KR102115735B1 (en) * 2015-11-05 2020-06-05 미쯔비시 케미컬 주식회사 Continuous carbon fiber bundle, sheet molding compound, and fiber-reinforced composite material molded using the same
CN105552794A (en) * 2016-02-05 2016-05-04 嘉兴学院 Automobile line protection sleeve
CN109715385B (en) 2016-09-14 2021-04-27 三菱化学株式会社 Laminated substrate and method for producing same
CN108690347B (en) * 2017-04-10 2022-07-12 广州金发碳纤维新材料发展有限公司 Carbon fiber reinforced nylon composite material and preparation method thereof
WO2019172247A1 (en) * 2018-03-06 2019-09-12 東レ株式会社 Carbon fiber bundle and production method therefor
KR102079371B1 (en) * 2018-08-01 2020-02-19 한국생산기술연구원 Method for preparation of heat-sink compound
KR102143024B1 (en) * 2019-06-17 2020-08-11 한국생산기술연구원 Method for preparation of heat-sink silicone elastomer compound
DE102019125531A1 (en) * 2019-09-23 2021-03-25 Newcycle Kunststofftechnik Gmbh Method for producing carbon fiber strand sections, method for reinforcing components, carbon fiber strand section production device and component production device
CN111117203A (en) * 2019-12-12 2020-05-08 上海普利特伴泰材料科技有限公司 Conductive, high-mechanical-property and low-warpage fiber-reinforced polyphenyl ether composite material and preparation method thereof

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JP4161409B2 (en) * 1997-05-23 2008-10-08 東レ株式会社 Chopped carbon fiber and method for producing the same
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Also Published As

Publication number Publication date
DE69818344T2 (en) 2004-07-01
US6444187B1 (en) 2002-09-03
SG65070A1 (en) 1999-05-25
KR19980087324A (en) 1998-12-05
KR100479546B1 (en) 2005-08-31
US6066395A (en) 2000-05-23
MY114978A (en) 2003-02-28
CN1213025A (en) 1999-04-07
CN1105210C (en) 2003-04-09
EP0881312B1 (en) 2003-09-24
DE69818344D1 (en) 2003-10-30
EP0881312A2 (en) 1998-12-02
EP0881312A3 (en) 1998-12-09

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Legal Events

Date Code Title Description
FZDE Discontinued